Manufacturing system including modular assembly station for flexible manufacturing and optional automated component part feed system therefor

ABSTRACT

A manufacturing system including an apparatus in which a plurality differently configured workpieces requiring manufacturing operations are processed. The apparatus includes a work surface configured to receive apparatus components and a plurality of differently configured workpieces, a tool table adjacent the work surface providing support for tooling and apparatus components required to process various manufacturing operations on the workpieces, and a robotic manipulator positioned adjacent to the work surface and the tool table and having a gripping device configured to grip at least one of the apparatus components. Also, an automated feed system optionally included in the system for supplying component parts to the manufacturing operation. Also, a method of assembling first and second differently configured workpieces.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to U.S. Provisional Applications Nos.61/226,917 filed Jul. 20, 2009, and 61/278,849 filed Oct. 13, 2009, thecomplete disclosures of which are both incorporated herein by reference.

BACKGROUND OF THE INVENTION

a. Field of the Invention

The invention relates to the field of modular manufacturing systems, andautomated feed systems for supplying component parts thereto.

b. Description of the Related Art

Modern manufacturing has required ever-increasing complexity due to thedesire to manufacture multiple products on a single assembly line. Ithas proven increasingly difficult to produce, for example, both V-6 andV-8 engine cylinder heads or cylinder blocks, on a single assembly line.Therefore, manufacturers of these types of products have been requiredto design and manufacture duplicate assembly lines, for example, one fora V-6 engine cylinder head or cylinder block, and another for a V-8engine cylinder head or cylinder block. This has proven cost prohibitiveand driven up the cost to manufacture these types of products. Aparticular problem is related to the variation of production volumesbetween different products to be manufactured. For example, fullcapacity production of one type of engine cylinder head or cylinderblock might require 100,000 units per year, but not for several yearsafter production of that product begins. It is cost prohibitive toprepare an entire line that will be left idle during that period due tothe capital intensive requirements associated with preparing adesignated manufacturing line. Additionally, when one product is phasedout and another instituted, an entire assembly line can beunder-utilized or sitting idle for extended periods of time. This hasproven to be an unacceptable capital burden to the manufacturer ofengine cylinder heads or cylinder blocks and the like.

Therefore, it has become desirable to develop a new type ofmass-production manufacturing operation that can accommodate bothmultiple products and the variability associated with their respectiveproduction volumes.

Modern manufacturing operations have also required ever-increasingcomplexity due to the desire to manufacture multiple products on asingle assembly line or by alternative processes. Typically, an assemblyline is supplied with component parts by multiple feed systems, whichinclude a plurality of hoppers each containing a plurality of componentparts of the same type. For example, one of the hoppers contains acertain sized washer and another of the hoppers contains a certain sizedscrew, etc. Each of the hoppers is in communication with a dedicatedconveyor for moving the component parts in single file to the assemblyline. A robotic machine is in communication with each of the conveyorsfor properly orientating the component part and assembling it to aworkpiece to complete the product. Therefore, manufacturers haverequired long assembly lines to accommodate the plurality of suppliedcomponent part types, each type requiring its own hopper, conveyor androbotic machine, thus taking up large amounts of space for manufacturingthe products. Further, having multiple hoppers, multiple conveyors andmultiple robotic machines is cost prohibitive.

Therefore, a need remains to develop an automated feed system forsupplying various different component parts to an assembly operationthat eliminates multiple hoppers, multiple conveyors and multiplerobotic machines.

SUMMARY OF THE INVENTION

The inventive manufacturing system includes a modular assembly stationor apparatus by which workpieces of differing type or configuration maybe processed, the workpieces requiring different tool operations fortheir production. The manufacturing system includes a work surfaceconfigured to locate and retain assembly apparatus components, and onwhich one of a plurality of differently configured workpieces areaffixed, for processing. Assembly apparatus components may be retainedto the work surface through a plurality of receptors configured toengage and affix the assembly apparatus components, and one of theplurality of differently configured workpieces, to the work surface atgeometrically accurate locations. A tool table is positioned adjacentthe work surface and provides support and storage for tooling andassembly apparatus components required to perform the manufacturingoperation on the workpieces.

The system includes at least one robotic manipulator configured to gripat least one of the assembly apparatus components, the tooling, and oneof the plurality of differently configured workpieces, and to obtain,position and assemble to the workpiece a component part. The roboticmanipulator may be positioned adjacent to the work surface, the tooltable, and a workpiece delivery station, and may be programmed toselectively acquire assembly apparatus components and tooling from thetool table, component parts, and the workpieces, and to performmanufacturing operations on the plurality of differently configuredworkpieces, such as assembling the component parts thereto.

The manufacturing system solves problems associated with conventionalmoving assembly lines by making it possible to conduct manufacturingoperations that alter workpieces of different configurations withouthaving to dedicate an entire assembly line to each workpiececonfiguration. Through use of the inventive system, only the toolingnecessary for processing the various workpiece configurations isrequired, many of which are common to processes performed on thedifferent workpiece configurations. The tool table can hold multipletools and assembly apparatus components required for performingprocesses on differently configured workpieces. To accommodate varyingdemand and production volumes for different workpiece configurations,the system can selectively process and produce the different workpiececonfigurations using multiple tooling and assembly apparatus componentswith minimal redundancy, and thus provides improvements overconventional moving assembly lines.

The manufacturing system may also include an optional automated feedsystem for supplying a plurality of different types of component partsto the modular assembly apparatus for use in the manufacturingoperation. The component part feed system includes a hopper forreceiving a plurality of differently configured component parts, and aconveyor in communication with the hopper. The conveyor includes aproximal end and a distal end with the hopper disposed adjacent theproximal end. The hopper cooperates with the conveyor for moving thedifferent types of component parts from the proximal end to the distalend.

Opposing side rails extend between the proximal and distal ends of theconveyor for guiding a potentially mixed variety of component parts fromthe hopper toward the distal end, at which the component parts arriveone at a time, in single file fashion. A component part roboticmanipulator, movable along a track that may extend laterally relative tothe direction of conveyor belt movement, is provided for acquiring thecomponent parts individually at the conveyor distal end and relocatingthem away from the conveyor. An identifier is disposed adjacent thedistal end for identifying the type of component part present, anddetermining whether the identified component part requires reorientationby the component part robotic manipulator prior to it being supplied tothe manufacturing operation.

The automated component part feed system solves problems associated withprior feed systems for supplying manufacturing operations with componentparts, by making it possible to process a plurality of differentcomponent parts utilizing one hopper, one conveyor and one componentpart robotic manipulator without having to duplicate thehoppers/conveyors/robotic manipulators for each of the differentcomponent part types needed in the manufacturing operation. Theautomated component part feed system reduces manufacturing costs byeliminating duplicate component part feed systems, their associatedspace requirements, and the need for skilled laborers to move up anddown the assembly line adding a different type of component part to eachof the respective, dedicated hoppers.

The present invention provides a manufacturing system including anapparatus in which a plurality differently configured workpiecesrequiring manufacturing operations are processed. The apparatus includesa work surface configured to receive apparatus components and aplurality of differently configured workpieces, the work surfaceconfigured to support the apparatus components and the plurality ofdifferently configured workpiece in geometrically accurate locations.The apparatus also includes a tool table adjacent the work surfaceproviding support for tooling and apparatus components required toprocess various manufacturing operations on the workpieces. Theapparatus also includes a robotic manipulator positioned adjacent to thework surface and the tool table and having a gripping device configuredto grip at least one of the apparatus components. At least one ofapparatus components is moved by the first robotic manipulator betweenthe tool table and the work surface, and the robotic manipulator isprogrammed to selectively acquire tooling from the tool table to performmanufacturing operations on the plurality of differently configuredworkpieces.

The present invention also provides a method of assembling first andsecond differently configured workpieces, including the steps of:releasably affixing first assembly apparatus components to a worksurface using at least one of a plurality of receptors positioned in ageometrically accurate location; releasably affixing the first workpieceto the work surface using at least one of the plurality of receptorsthereby positioning the first workpiece in a geometrically accuratelocation; supporting assembly apparatus components necessary to assemblethe first workpiece relative to the work surface; positioning a roboticmanipulator carrying tooling necessary to assemble the first workpieceand the first component part relative to the first workpiece; supportingtooling necessary to assemble the first workpiece against undesiredmovement relative to the first workpiece with at least one of anassembly apparatus component and the work surface; performing a firstassembly operation by operating the tooling and installing the componentpart to the first workpiece; removing the first workpiece from the worksurface; releasably affixing second assembly apparatus components to thework surface using at least one of the plurality of receptors positionedin a geometrically accurate location; releasably affixing the secondworkpiece to the work surface using at least one of the plurality ofreceptors thereby positioning the second workpiece in a geometricallyaccurate location; supporting assembly apparatus components necessary toassemble the first workpiece relative to the work surface; positioning arobotic manipulator carrying tooling necessary to assemble the secondworkpiece and a component part relative to the second workpiece;supporting tooling necessary to assemble the second workpiece againstundesired movement relative to the second workpiece with at least one ofan assembly apparatus component and the work surface; performing asecond assembly operation by operating the tooling and installing thecomponent part to the second workpiece; and removing the secondworkpiece from the work surface.

The present invention also provides an automated feed system forsupplying component parts to a manufacturing operation. The feed systemincludes a hopper for receiving a plurality of differently configuredcomponent parts and a conveyor in communication with the hopper andhaving a proximal end and a distal end. The hopper is disposed adjacentthe proximal end with the hopper cooperating with the conveyor formoving the component parts from the proximal end toward the distal end.Opposing side rails extend between the hopper and the conveyor distalend for guiding the component parts toward the distal end. The feedsystem also includes a robotic manipulator movable along a track formoving the component parts from the distal end and away from theconveyor, and an identifier disposed adjacent the distal end with theidentifier in communication with the robotic manipulator, each of thecomponent parts identified by the identifier.

BRIEF DESCRIPTION OF THE DRAWINGS

Advantages of the present invention will be readily appreciated as thesame becomes better understood by reference to the following detaileddescription when considered in connection with the accompanyingdrawings, wherein:

FIG. 1 is an upper perspective view of a manufacturing system includinga first embodiment modular assembly station or apparatus, and anoptional automated component part feed system connected thereto;

FIG. 2 is an upper perspective view of the modular assembly apparatus ofFIG. 1, showing it adapted for processing a workpiece of a first type orconfiguration;

FIG. 3 is a view similar to FIG. 2, showing it adapted for processing aworkpiece of a second, different type or configuration;

FIG. 4 is an upper perspective view of an alternative, second embodimentmodular assembly station or apparatus that may instead be included inthe manufacturing system of FIG. 1;

FIG. 5 is an upper perspective view of a frame for the modular assemblyapparatus of FIG. 4;

FIG. 6 is an upper perspective view of the work surface and tool tableassociated with a subportion of the modular assembly apparatus of FIG.4;

FIG. 7 is an upper perspective view of the modular assembly apparatus ofFIG. 4, showing it adapted for processing a workpiece of a first type orconfiguration;

FIG. 8 is an upper perspective view of a robotic manipulator of themodular assembly apparatus of FIG. 4 moving a leak test seal plate intoposition on a workpiece and seal plate affixed to the work surface;

FIG. 9 is an upper perspective view of the modular assembly apparatus ofFIG. 4 showing a workpiece being moved toward its fixture or adapter onthe work surface;

FIG. 10 is similar to FIG. 9, but shows an anvil mounted on the worksurface and a different robotic manipulator gripping device for graspinga different type of or differently configured workpiece;

FIG. 11 is a fragmentary upper perspective view of the work surfaceassociated with the first embodiment modular assembly apparatus of FIG.1, showing a registry attached thereto;

FIG. 12 is a view similar to FIG. 11, showing an adapter attached to theregistry;

FIG. 13 is a view similar to FIG. 12, showing a workpiece attached tothe adapter;

FIG. 14 is a fragmentary view of the work surface associated with themodular assembly apparatus of FIG. 1 with a workpiece mounted thereon,in place atop the adapter, and the end of the robot manipulator boomwith a press ram tool head attached thereto;

FIG. 15 is a fragmentary view of the work surface associated with themodular assembly apparatus of FIG. 1 with a workpiece mounted thereon,in place atop the adapter and the end of the robot manipulator boom witha torquing tool head attached thereto;

FIG. 16 is a fragmentary view of the modular assembly apparatus of FIG.1 showing the end of the robot manipulator boom with press ram tool headattached thereto positioned proximate to and aligned with a componentpart receiving station connected to the optional automated componentpart feed system;

FIG. 17 is an upper end view of the manufacturing system showing itsoptional automated component part feed system connected to its modularassembly apparatus; and

FIG. 18 is a partial, overhead view of the manufacturing system showingits optional automated component part feed system of FIGS. 1 and 17connected to the component part receiving stations of its modularassembly apparatus.

While the invention is susceptible to various modifications andalternative forms, specific embodiments thereof are shown by way ofexample in the drawings and may herein be described in detail. It shouldbe understood, however, that the drawings and detailed description arenot intended to limit the invention to the particular form(s) disclosed,but on the contrary, the intention is to cover all modifications,equivalents and alternatives falling within the spirit and scope of thepresent invention as defined by the appended claims.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENT(S)

The following description of the preferred embodiment(s) is merelyexemplary in nature and is in no way intended to limit the invention, orits uses. It is to be noted that the figures are not necessarily drawnto scale. In particular, the scale of some of the elements of thefigures may be exaggerated to emphasize characteristics of the elements.It is also noted that the figures are not drawn to the same scale.Elements shown in more than one figure that may be similarly configuredhave been indicated using the same reference numerals.

Disclosed herein is a flexible, modular manufacturing system by whichmanufacturing operations are performed on a plurality of workpieces 100that are of different configurations or types. For example, workpieces100 may be V8 and V6 engine blocks or cylinder heads that requirevarious different component parts 104 to be assembled thereto. Inconnection with the exemplary manufacturing system embodiments discussedherein, the workpieces 100 are shown as engine cylinder heads 100 a and100 b of differing, V8 and V6 configurations, respectively. It is to beunderstood that workpieces of different types or configurations may beprocessed generally as described. Each exemplary workpiece 100 has atleast one component part 104 assembled thereto by manufacturing system110. Each component part 104 may be one of a plurality of differentcomponent parts, herein identified as four different component parts 104a, 104 b, 104 c, and 104 d that may be of differing type, size,function, attachment structure, etc. For example, component part 104 amay be of a type that is interference-fitted into an aperture 106 a ofworkpiece 100, whereas component part 104 b may be of a type that isthreadedly received into a threaded hole 106 b in workpiece 100.Component part 104 a may, for example, be a sealing plug and componentpart 104 b may, for example, be an engine control coolant temperaturesensor. The component parts 104 may also be other types of plugs orsensors, washers, screws, bolts, sprockets, gears, or any other type ofcomponent part, of any required size and configuration, suitable for aproduct workpiece 100 processed by manufacturing system 110.

Manufacturing system 110 includes a modular assembly apparatus orstation in which a manufacturing operation is performed on theworkpieces 100. In the particular example embodiments discussed herein,the manufacturing operations performed by system 110 involve assembly ofat least one component part 104 a, 104 b, 104 c, 104 d to a workpiece100 a, 100 b, and leak testing the assembled workpieces. Manufacturingsystem 110 may include first embodiment assembly apparatus 120 or secondembodiment assembly apparatus 220, both described further herein below.

Generally, the first and second assembly station embodiments 120, 220are similar in function and structure. Each has a work surface supportedby a frame and to which apparatus components, such as a registry,workpiece mounting fixtures or adapters, tool-supporting anvils, and/orleak test plates, are selectively attached at geometrically accuratelocations. Assembly stations 120, 220 further include a tool table onwhich interchangeable tooling and apparatus components are placed atrespective, designated geometrically accurate locations. Assemblystations 120, 220 are provided with a supply at least one component parttype, and includes at least one robotic manipulator. The component partsupply of the assembly apparatus 120, 220 may include a receivingstation connected to the optional automated component part feed systemdescribed further below.

A primary difference between assembly stations 120 and 220 is thatassembly station 220 includes a pair of robotic manipulators which canboth, or each, be utilized for setting up the work surface, whichincludes selecting and positioning the apparatus components and theworkpiece 100, and performing the manufacturing operations, whereasassembly station 120 may include a single robotic manipulator that canperform all of these aspects of the manufacturing operation.

Tool tables 138, 238 of the respective assembly apparatuses 120, 220support various tooling necessary to perform manufacturing operations onthe differently configured workpieces 100 a, 100 b. Therefore, a singleassembly apparatus 120 or 220 is capable of processing multipledifferent configurations or types of workpieces 100 without requiringduplicative assembly apparatuses. This facilitates the balancing ofmanufacturing flow to eliminate possible bottlenecks in a manufacturingoperation.

For example, a particular manufacturing facility might receive an orderfor 50,000 V-8 engine cylinder heads 100 a and 60,000 V-6 enginecylinder heads 100 b. Alternatively, the lead time for V-8 cylinderheads 100 a might be spread over six months, but the V-6 cylinder heads100 b are required for delivery within two months. A manufacturer, bymaking use of manufacturing system 110, can balance its productionrequirements by having to acquire only the additional fixtures andtooling to meet the actual, current production requirements rather thanalso the projected, future production requirements, and is thus notrequired to acquire additional entire assembly apparatuses 120, 220. Theacquisition of any additional apparatuses 120, 220 can be deferred untilit is necessary to actually produce higher production volumes.

Referring to FIGS. 1-3, manufacturing system 110 may include, or bepositioned adjacent to, a workpiece conveyor 112 along which theplurality of differently configured workpieces 100 a, 100 b are movedand from which they are supplied to the manufacturing operation.Workpiece conveyor 112 may have a position 114 therealong that defines adelivery station from which a workpiece 100 to be processed in assemblystation 120, 220 is obtained by its robotic manipulator, as describedabove. The configuration or type of workpiece (e.g., 100 a or 100 b)arriving at delivery station 114 may be predefined, or recognized uponits arrival at delivery station 114 by a suitable sensor 116 such as,for example, an optical image identifier, bar code reader, magnetic codesensor, etc., all of which are known to those of ordinary skill in theart. After a workpiece 100 has completed its processing in assemblystation 120, 220, its robotic manipulator may return the workpiece todelivery station 114, relocate it to another conveyance or assembly lineproximate to the assembly station, or place it in nearby dunnage fortransport elsewhere.

Additionally, as described further below with reference to assemblystation 220, leak and/or pressure testing may be performed in assemblystation 120, 220 on workpieces 100 produced by manufacturing system 110.Such testing may be performed utilizing either assembly stationembodiment 120, 220 herein disclosed, which may be provided withhydraulic or pneumatic fluid pressurization capabilities, and associatedpressure sensing equipment of a mechanical or electrical type.

Robot gripping device or tool head interconnection to a roboticmanipulator, or assembly apparatus component interconnection to a worksurface, regardless of particular embodiment, may be through use ofsuitable collet and balls-type changers of a type available, forexample, from ATI Industrial Automation of Apex, N.C.

The assembly station 120, 220 of manufacturing system 110 may beconnected to an optional automated component part feed system 310. Asdescribed below with reference to assembly station 120, component partreceiving stations are positioned at geometrically accurate locations inboth assembly station embodiments 120, 220, each receiving stationassociated with a particular one of a plurality of different types ofcomponent parts 104 supplied to the manufacturing operation. A roboticmanipulator of the assembly station 120, 220 obtains with a suitableattached tool the necessary component part 104 which has been suppliedby the component part feed system 310 to the respective receivingstation, positions the component part relative to the workpiece 100, andassembles it to the workpiece.

Referring to FIGS. 1-3 and 11-16, first embodiment modular assemblystation or apparatus 120 of manufacturing system 110 is shown.

Modular assembly station 120 includes work surface 122 mounted uponframe 124. First and optional second manipulator platforms 126, 128 aredisposed on opposite sides of and adjacent to the work surface 122.Platform 126 is also mounted to the frame 124. Optional second platform128 may be located outside of the work cell in which work surface 122and first manipulator platform 126 are contained, but is consideredadjacent to work surface 122 with which may interact.

A first robotic manipulator 130 is mounted upon the first manipulatorplatform 126 and an optional second robotic manipulator 132 is mountedupon the second manipulator platform 128. Although it is contemplatedthat robotic manipulator 130 may carry out all robotic manufacturingoperations on workpieces 100, optional second robotic manipulator 132may be particularly useful for moving workpieces that have completedprocessing to a conveyance other than workpiece conveyor 112, to anassembly line, or to place the processed workpieces in dunnage fortransport elsewhere. Compared to first robotic manipulator 130, optionalsecond robotic manipulator 132 may be larger, with longer reach andhigher capacity, and better suited to lifting and transferring large,heavy workpieces 100, between work surface 122 and the workpiecedelivery station 114. Further, as mentioned above, it may be desirablethat the workpiece 100, once its processing in assembly apparatus 120 iscomplete, be transferred from the work surface 122 to a location outsideof the assembly station other than delivery station 114, such as anotherconveyance, an assembly line, or nearby dunnage for transport elsewhere;providing assembly apparatus 120 of manufacturing system 110 withoptional second robotic manipulator 132 would better facilitate suchtransference. Robotic manipulators 130, 132 are controlled by controller134 and electronics panel 136 in a manner well known to those ofordinary skill in the art.

A tool table 138 is also mounted on the frame 124, adjacent to the worksurface 122. The tool table 138, work surface 122, and roboticmanipulators 130, 132 are each arranged in a geometrically accuratelocation, as are component part receiving stations 170, from whichcomponent parts 104 are supplied to the manufacturing operation.Component part receiving stations 170 may be connected to optionalcomponent part feed system 310 via dispatching lanes 316.

Referring to FIGS. 1-3, frame 124 includes peripheral walls 140 thatsurround work surface 122, and which provide support to anvils 162placed on work surface 122. Alternatively, anvil receptors in worksurface 122 may be used for positioning and affixing anvils 162 to thework surface, in the manner described below in connection with secondembodiment assembly apparatus 220. Frame 124 also includes overheadsupport structure 142 to which an anvil 162 is affixed. Anvils 162present reaction surfaces that interface the workpiece and supportrobotic manipulator-mounted tools as they perform work on the workpiece.Any of peripheral walls 140, overhead support structure 142, and anvils162 may be included, moved towards or away from the location ofworkpiece 100 as mounted on work surface 122, or omitted entirely,depending on the manufacturing operation needs.

Referring to FIG. 11, registry receptors 146 extending from work surface122 are adapted to engage the workpiece fixture registry 148 in responseto pneumatic, electrical, or electronic inputs, and thereby secure theregistry 148 to the work surface 122. Further, the registry 148 andregistry receptors 146 may be adapted to actuate locking devices 152 ofadapter 150 for engagement of the workpiece 100 in response to amechanical, pneumatic, electrical, or electronic output from theregistry 148, the output being produced in response to registry inputfrom the receptor 146.

FIGS. 1 and 2 show the modular assembly apparatus 120 preparing toperform a manufacturing operation on a workpiece 100. The workpiece 100arrives at delivery station 114 on workpiece conveyor 112 (FIG. 1), andis known to be, or is there sensed as being a particular one of theplurality of different workpiece configurations 100 a, 100 b. In thisnon-limiting example, workpiece fixtures or adapters 150 a and 150 b,which are particularly configured to support their respective workpieces100 a and 100 b, are stored in their respective, geometrically accuratepositions on tool table 138. An adapter 150 corresponding to the type orconfiguration of the present workpiece 100 is acquired from tool table138 by first robotic manipulator 130 using its robotic gripper, andrelocated to the work surface 122, where it is secured in ageometrically accurate location to the work surface 122 through registry148 and registry receptors 146.

The workpiece 100 is then grasped by the first robotic manipulator 130,or by the optional second robotic manipulator 132 using its roboticgripper 154, which is removably attached to the end of the robot's boom155. The workpiece 100 is relocated from delivery station 114 toassembly station 120, and delivered to the workpiece fixture or adapter150 that is mounted to the work surface 122 through registry 148. In aknown manner, mechanical, electronic or pneumatic inputs are providedthrough the work surface 122 and registry 148, to the workpiece fixtureor adapter 150, to actuate locking devices 152 in the workpiece fixtureor adapter 150. Locking devices 152 secure the workpiece 100 to theadapter 150, and thus to registry 148 and work surface 122, in ageometrically accurate location.

In this non-limiting example, the first robotic manipulator 130 isarticulated to the tool table 138, and using its gripping device graspsone of a plurality of anvils 162, each of which is stored in aparticular position on the tool table. Each of anvils 162 may correspondto the type or configuration of workpiece 100; or some or all of anvils162 may be generic to all workpiece configurations. One or more ofanvils 162 are acquired from tool table 138 by first robotic manipulator130 and relocated one-by-one to the work surface 122, where they arepositioned on work surface 122 against peripheral wall 140 ingeometrically accurate locations. In other words, in this non-limitingexample, the first robotic manipulator 130 has mounted anvils 162 uponthe work surface 122 by placing them in abutting contact with peripheralwall 140. Alternatively, or additionally, anvils 162 may be affixed tothe work surface 122 via anvil receptors as described below inconnection with second embodiment assembly apparatus 220. By eitheralternative, anvils 162 are thus releasably mountable on work surface122, and support frame 124 provides support through anvils 162 for thetool head 158 of robotic manipulator 130, 132 that manipulates a tool160 for performing work on the workpiece 100.

The first robotic manipulator 130, once having positioned the workpiecefixture or adapter 150 on work surface 122, is then articulated to thetool table 138 to place its gripper in its designated position, releaseit, and engage a manufacturing tool head 158. Alternatively, optionalsecond robotic manipulator 132, once having positioned workpiece 100 onworkpiece fixture or adapter 150, may then be articulated to the tooltable to place gripper 154 in its designated position, release it, andengage a manufacturing tool head 158. Each tool head 158 may be one of aplurality of different types, sizes and capacities. In this example,tool head 158 is a press ram type head 158 a or a torquing type head 158b, which respectively drive an interfitted tool 160 linearly (in thecase of tool head 158 a) or linearly and rotationally (in the case oftool head 158 b), relative to the workpiece 100 when installing acomponent part 104.

The interfitted tool 160 a, 160 b of each respective type of tool head158 a, 158 b is one of a plurality of interchangeable tools 160 a, 160b, 160 c, 160 d, each having a particular storage position on tool table138, and the robotic manipulator with tool head 158 a or 158 b attachedthereto, is articulated to acquire and interfittingly engage one ofinterchangeable tools 160 appropriate for the component part 104 to beinstalled on workpiece 100. Alternatively, tool 160 may be the sole tool160 a or 160 b used with the respective type of tool head 158 a or 158b, and may remain interfittingly engaged with its tool head 158.

Referring to FIGS. 4-10, alternative second embodiment modular assemblystation or apparatus 220 of manufacturing system 110 is shown. Modularassembly station 220 includes work surface 222 mounted upon frame 224.First and second manipulator platforms 226, 228 are disposed on oppositesides of and adjacent to the work surface 222. Each of the platforms226, 228 is also mounted to the frame 224.

A first robotic manipulator 230 is mounted upon the first manipulatorplatform 226 and a second robotic manipulator 232 is mounted upon thesecond manipulator platform 228. Although it is contemplated that eachrobotic manipulator 230, 232 may have a designated task in carrying outthe manufacturing operations on workpieces 100 a, 100 b, it is preferredthat the robotic manipulators 230, 232 each be able to perform some ifnot all of the robotic manufacturing operations within assembly station220. Robotic manipulators 230, 232 are controlled by controller 234 andelectronics panel 236 in a manner well known to those of ordinary skillin the art.

A tool table 238 is also mounted on the frame 224, adjacent to the worksurface 222. The tool table 238, work surface 222, and roboticmanipulators 230, 232 are each arranged in a geometrically accuratelocation, as are component part receiving stations 270, which aresubstantially identical to receiving stations 170 of assembly apparatus120.

Referring to FIG. 5, frame 224 includes width-wise cross members 240 andlength-wise cross members 242 to provide support for the work surface222 and the first and second manipulator platforms 226, 228 asnecessary. The width-wise cross members 240 are connected to thelength-wise cross members 242 and to longitudinal rails 244 viaintermediate walls 246.

Referring now to FIG. 6, a subportion of the assembly apparatus 220 isgenerally shown at 248. Workpiece fixture or registry receptors 250 arecentrally located on the work surface 222. Receptors 250 aregeometrically located in a dimensionally accurate location. Likewise,anvil receptors 252 are spaced around the work surface 222 in ageometrically accurate location relative to the registry receptors 250.Each of the receptors 250, 252 can be adapted to engage the workpiecefixture registry or the anvils in response to pneumatic, electrical, orelectronic inputs, and thereby secure the registry and anvils to thework surface 222. Further, the registry and registry receptors 250 maybe adapted to actuate adapter or workpiece fixture 256 for engagement ofthe workpiece 100 in response to a pneumatic, electrical, or electronicoutput from the registry, the output being produced in response toregistry input from the receptor 250.

Moreover, it is envisioned that registry receptors 250 in particular maybe utilized to conduct fluid to and from the workpiece, and/or toprovide electrical instrumentation connections, for conductingpost-assembly process leak tests within assembly apparatus 220.Additionally, various other ports (not shown) may be used to provideinputs at desired locations in work surface 222.

FIG. 7 shows the modular assembly apparatus 220 preparing to perform amanufacturing operation on a workpiece 100. The workpiece 100 arrives atdelivery station 114 on workpiece conveyor 112 (FIG. 1), and is known tobe, or is there sensed as being a particular one of the plurality ofdifferent workpiece configurations 100 a, 100 b. In this non-limitingexample, workpiece fixtures or adapters 256 a and 256 b, which areparticularly configured to support their respective workpieces 100 a and100 b, are stored in their respective, geometrically accurate positionson tool table 238. An adapter 256 corresponding to the type orconfiguration of the present workpiece 100 is acquired from tool table238 by first robotic manipulator 230 using its robotic gripper 257, andrelocated to the work surface 222, where it is secured in ageometrically accurate location to the work surface 222 directly orthrough an intermediate registry, via registry receptors 250.

The workpiece 100 is grasped by the second robotic manipulator 232 usingits robotic gripper 254, which is removably attached to the end of therobot's boom 255, and relocated from delivery station 114 to assemblystation 220. The second robotic manipulator 232 delivers the workpiece100 to the workpiece fixture or adapter 256 that is mounted to the worksurface 222. In a known manner, electronic or pneumatic inputs areprovided through the work surface 222 and registry, to the workpiecefixture or adapter 256, to actuate locking devices (not shown) in theworkpiece fixture or adapter 256. These locking devices secure theworkpiece 100 to the workpiece fixture or adapter 256, and thus to worksurface 222, in a geometrically accurate location.

In this non-limiting example, the first robotic manipulator 230 isarticulated to the tool table 238, and using gripping device 257 graspsone of a plurality of anvils 262, each of which is stored in aparticular position on the tool table. Each of anvils 262 may correspondto the type or configuration of workpiece 100; or some or all of anvils262 may be generic to all workpiece configurations. One or more ofanvils 262 are acquired from tool table 238 by first robotic manipulator230 and relocated one-by-one to the work surface 222, where they aresecured in a geometrically accurate location to the work surface 222 viaanvil receptors 252. In this non-limiting example, the first roboticmanipulator 230 has installed anvils 262 upon the work surface 222 viaanvil receptors 252, although one of ordinary skill in the art willrecognize that second robotic manipulator 232 may perform this functionusing its gripper 254.

The first robotic manipulator 230, once having positioned the workpiecefixture or adapter 256 and anvils 262 on work surface 222, is thenarticulated to the tool table 238 to place gripper 257 in its designatedposition, release it, and engage a manufacturing tool head 258.Alternatively, second robotic manipulator 230, once having positionedworkpiece 100 on workpiece fixture or adapter 256, may then bearticulated to the tool table to place gripper 254 in its designatedposition, release it, and engage a manufacturing tool head 258. Eachtool head 258 may be one of a plurality of different types, sizes andcapacities. In this example, tool head 258 is either a press ram typehead 258 a or a torquing type head 258 b, which respectively drive aninterfitted tool 260 linearly and/or rotationally relative to theworkpiece 100 when installing a component part 104.

The interfitted tool 260 a, 260 b of each respective type of tool head258 a, 258 b may be one of a plurality of interchangeable tools (such astools 160 a-d described above) having a particular storage position ontool table 238, and the robotic manipulator (e.g. 230) with tool head258 a or 258 b attached thereto, is articulated to acquire andinterfittedly engage a suitable interchangeable tool 260 (for example,such as one of tools 160 a-d described above). Alternatively, tool 260may be the sole tool 260 a or 260 b used with the respective type oftool head 258 a or 258 b, and may remain interfittingly engaged with itstool head 258, as shown in FIGS. 7-10.

FIGS. 9 and 10 show various tools used to perform manufacturing work ona workpiece 100. FIG. 9 shows the second robotic manipulator 232 movinga workpiece 100 from delivery station 114 to a workpiece fixture oradapter 256 mounted on the work surface 222. The first roboticmanipulator 230 is shown with torquing tool head 258 b coupled to itsboom 268. Alternatively, first robotic manipulator 230 with grippingdevice 257 may be used for acquiring and affixing an anvil 262 to thework surface 222. FIG. 10 shows one anvil 262 that has been mounted tothe work surface 222 by the first robotic manipulator 230, which now haspress ram tool head 258 a attached to its boom 268. FIG. 10 shows analternative gripping device 272 affixed to the second roboticmanipulator 232, which can be used instead of gripping device 254 forgrasping an alternative type of workpiece 100 if its configurationdiffers sufficiently from the other type of workpieces. In this example,the alternative gripping device 272 is normally stored on the tool table238 and is interchanged by the second robotic manipulator 232.

Regardless of whether manufacturing system 110 includes first or secondembodiment modular assembly station or apparatus 120 or 220, the roboticmanipulator to which the tool head 158, 258 is releasably coupledpreferably obtains the respective component part 104 from its componentpart receiving station 170, 270 which may be connected to optionalautomated component part feed system 310.

The tool 160, 260 with which a particular component part 104 is obtainedfrom its receiving station 170, 270 is adapted to engage and retain thecomponent part 104 (for example, by an interference fit or a springclip), and hold it securely in a particular orientation relative to thetool head 158, 258 as the tool head is moved with component part 104attached to tool 160, 260. The tool head 158, 258 is moved fromreceiving station 170, 270 and positioned proximate to workpiece 100with component part 104 axially aligned with workpiece aperture or hole106 a, 106 b.

With reference to FIGS. 14 and 15, to reduce the amount of strain knownto damage and wear out joints of robotic manipulators, the tool head maybe brought into abutting contact with the anvil 162, 262 thatcorresponds with the aperture or hole 106 a, 106 b. The tool head 158,258 is positioned such that tool 160, 260 and its retained componentpart 104 are aligned with aperture 106 a or threaded hole 106 b inworkpiece 100. That is, the robotic manipulator will position itsattached tool head 258 into abutment against the surface of the anvil262 that is in interfacing relationship with the aperture 106 a orthreaded hole 106 b in workpiece 100 into which component part 104 willbe fitted. Once so positioned and abutting anvil 162, 262, tool head158, 258 is preferably unlocked relative to robotic manipulator boomsuch that it is unrestrained, and permitted to float relative to theboom, in the axial directions along which tool 160, 260 is linearlystroked in moving towards and away from workpiece 100, as indicated byarrow 166 in FIGS. 14 and 15, for example. The distance of the linearstroke may, for example, be from 0.5 inch to five inches. A press ramtool head 158 a, 258 a may, for example, be of known servomotor orhydraulic type, the latter suitably provided with fluid fittings, lines,and a controlled source of hydraulic fluid. A torquing tool head 158 b,258 b may, for example, be of known pneumatic or electronic type.

The anvil 162, 262 provides an axial reaction surface against which toolhead 158 bears as the component part 104 is forced axially into ortoward the workpiece 100, this is particularly important where press ramtool head 158 a, 258 a is being used, as depicted in FIG. 14, which mayinduce a pressing force of about 1500 pounds in installing a componentpart 104 (e.g., an interference-fitted plug) into a bore 106 a inworkpiece 100. It is believed that a torque head 158 b, 258 b, such asdepicted in FIG. 15, will not require the use of an anvil 162, 262 asshown for creating an axial reaction surface during a screwingoperation; thus the use of an anvil 162, 262 with a torque head 158 b,258 b is considered to be optional and not required for screwingoperations. Referring to FIGS. 9 and 15, a torquing tool head such as158 b or 258 b may include a laterally extending outrigger 159, 259, thefoot or terminal end of which is in abutting contact with work surface122, 222 which serves as a reaction surface that torsionally supportsthe tool head 158 b, 258 b to counteract the tightening torque of therotating tool 160, 260 as its threaded component part 104 is tightenedinto threaded hole 106 b in workpiece 100.

Once work by a particular tool head or its tool has been performed uponthe workpiece 100, the tool head 158, 258 is moved by the roboticmanipulator to the tool table 138, 238, where the tool 160, 260 isreturned to its designated place on tool table and another tool, or toolhead and tool, acquired as applicable. If a different tool head 158, 258and/or tool 160, 260 is acquired a different component part 104 may beacquired from its respective receiving station 170, 270 and processingof workpiece 100 continues.

When all of the work operations have been completed upon the workpiece100, the workpiece 100 is removed from the work surface 122, 222 by arobotic manipulator and returned to delivery station 114 or transferredto another conveyance, assembly line or dunnage as described above.

In some instances, it is necessary to test the workpiece 100 for leaks.It may be preferable that leak testing be done in assembly apparatus120, 220, prior to removing the workpiece 100 from system 100 aftercompletion of the manufacturing operation. One example is for an engineblock or cylinder head workpiece (e.g., workpiece 100) that hasundergone the assembly process in apparatus 120, 220 to be sealed andinternally provided with pressurized fluid to verify that the installedcomponent parts 104 (e.g., plugs or sensors) are dimensionally accurateand correctly seal fluid passages in the workpiece. Therefore, the worksurface 122, 222 may by adapted to receive assembly apparatus leak testcomponents to ensure the fluidic integrity of the workpiece 100. Suchfurther processing may be done by a manufacturing system 110 utilizingeither assembly apparatus 120 or 220, but the example below is describedwith respect to the latter.

A seal plate 264 is stored on tool table 238. Referring to FIG. 8, afterworkpiece 100 has completed its manufacturing operations (e.g., theinstallation of component parts 104), it is removed from its workpiecefixture or adapter 256, and its workpiece fixture or adapter 256 isremoved from its registry, and registry then removed from the worksurface 222. A seal plate 264 is mounted onto work surface 222 throughengagement with registry receptors 250. Seal plate 264 is configured toaccommodate the particular configuration of workpiece 100, and so a sealplate 264 a may be provided for leak testing workpiece 100 a, and a sealplate 264 b may be provided for leak testing workpiece 100 b. Workpiece100 is then placed on seal plate 264, and, if necessary, acts as amanifold for receiving or routing pneumatic or hydraulic pressurereceived through work surface, to internal passages of workpiece 100.Seal plate 264 may include locking devices (not shown) similar to thoseof workpiece fixture or adapter 256 for engagement with workpiece 100.Workpiece 100 is thus fixed through seal plate 264 to work surface 222.

A longitudinal leak test seal plate 266, which may be common for usewith both workpiece configurations, is stored on the tool table 238.Still referring to FIG. 8, longitudinal leak test seal plate 266 ismoved by the second robotic manipulator 232 from the tool table 238 andplaced atop the workpiece 100 and seal plate 264. The longitudinal leaktest seal plate 266 includes piping and wiring to receive eitherpneumatic or hydraulic pressure from delivery ports mounted either inthe seal plate 264 or on the work surface 222. The wiring may beelectrically connected to the electronics panel 236 through electricalconnectors (not shown) in the work surface 222 to provide pressureindication readings through the electronics panel 236 to the controller234 to determine if any leaks exist in the manufactured workpiece 100.Alternatively, mechanical measurements can be made that do not requirepiping or wiring.

The longitudinal leak test seal plate 266 is secured to the seal plate264 via a threaded rod (not shown) secured by robotic manipulator 230, atorquing tool head and a torquing tool such as head 258 b and tool 260b. Once seal plate 266 is secured over ports in workpiece 100, pressuredfluid is conducted through seal plate 264 to workpiece 100, which ischecked for leaks indicated by sensed pressure changes therein. Itshould be understood by those of skill in the art that alternative leaktest seal plates may be required to conduct a leak test of various,differently configured workpieces 100.

Manufacturing system 110 may include automated component part feedsystem 310 optionally connected to modular assembly apparatus or station120 or 220. Feed system 310 supplies assembly stations 120, 220 with aplurality of different component part types 104, at least one of theplurality of different component parts 104 assembled to one or bothtypes of workpieces 100 a, 100 b.

The automated component part feed system 310 includes a workstation 312for separating and identifying a plurality of different types ofcomponent parts 104 a-d and for moving the component parts 104 to therespective dispatching station 314 a-d of the appropriate dispatchinglane 316 a-d. One type of the component part 104 a, 104 b, 104 c, or 104d is conveyed from component part feed system 310 to assembly apparatus120, 220 by the associated one of the dispatching lanes 316 a-dextending therebetween, as discussed further below. The component parts104 can be washers, screws, bolts, sprockets, gears, plugs, sensors orany other suitable type of component part for the product produced bymanufacturing system 110, one or more of component parts 104 a-d beingassembled in assembly station or apparatus 120, 220 to at least one ofworkpieces 100 a and 100 b. Generally, the component parts 104 arethreadedly attached or inserted/pressed into a workpiece 100 at assemblystation 120, 220.

The workstation 312 includes a hopper 318 and a conveyor 320 incommunication with the hopper 318. The hopper 318 receives all of theparts 104 and the conveyor 320 moves the parts 104 away from the hopper318. More specifically, the hopper 318 receives a plurality ofdifferently configured types of component parts 104 thus eliminating theneed for multiple hoppers and multiple conveyors as required by theprior art. The hopper 318 defines a top opening 322 into which aredumped or poured component parts 104. Component parts of a single type104 a, 104 b, 104 c, or 104 d may be dumped together into hopper 318, ora mixture of two or more different types of component parts 104 a-d maybe dumped together into hopper 318. The hopper 318 also defines a bottomopening 324 spaced from the top opening 322 and aligned with theconveyor 320 for moving the component parts 104 from the hopper 318 andonto the conveyor 320. The hopper 318 is preferably positioned above theconveyor 320 such that the parts 104 coming out of the bottom opening324 do not overlap each other on the conveyor 320. The hopper 318 alsoincludes a vibration or oscillation mechanism (not shown) for aiding inmoving the component parts 104 through the bottom opening 324. Thevibration or oscillation mechanism causes the hopper 318 to vibrate,pulse, shake, beat, tip or any other suitable movement for moving theparts 104 through the hopper bottom opening 324 and onto conveyor 320.

The conveyor 320 includes a distal end 326 and a proximal end 328 spacedfrom each other with the hopper 318 disposed adjacent the proximal end328 of the conveyor 320. The hopper 318 cooperates with the conveyor 320for moving the parts 104 from the proximal end 328 toward the distal end326. The conveyor 320 includes a longitudinally moveable endless belt330 rotating around the proximal and distal ends 328, 326 forcontinuously moving the parts 104 received from the hopper 318 towardthe distal end 326. One of ordinary skill in the art will appreciatethat the conveyor 320 can include chain links or any other suitablecomponent other than a belt 330 for moving the parts 104 toward thedistal end 326.

The conveyor 320 further includes opposing side rails 332 extendingvertically between the hopper 318 and the conveyor 320, and horizontallybetween the conveyor proximal and distal ends 328, 326. The side rails332 are laterally spaced from each other and are angled inwardly orconvergent toward the distal end 326 of the conveyor 320 for guiding thecomponent parts 104 together as they approach the distal end 326. Theends of converging sidewalls 332 are spaced near conveyor distal end 326to define an outlet opening 340 from which the various component parts104 emerge in a random, single file order. That is, each of componentparts 104 a-d individually passes through outlet opening 340 continuesin a single file line of parts 104 on belt 330 toward distal end 326.More specifically, the side rails 332 are spaced a first predetermineddistance from each other adjacent the hopper 318 and the side rails 332are spaced a second predetermined distance from each other adjacent thedistal end 326. The second predetermined distance, which defines outletopening 340, is less than the first predetermined distance such that thecomponent parts 104 are funneled into single file line on belt 330 atthe conveyor distal end 326.

The automated component part feed system 310 further includes acomponent part robotic manipulator 334 movable along a track 336 foracquiring each of the component parts 104 from the distal end 326 andmoving it away from the conveyor 320. The component part roboticmanipulator 334 includes a gripping device 335 for gripping each and anyof component parts 104 a-d, and moving it from distal end 326 to theappropriate dispatching station 314 a-d associated with a respective oneof dispatching lanes 316 a-d, one at a time. Gripping device may alsoadjust the position of a component part as necessary, such that it cangrip each type of component part 104 in a consistent manner forplacement in its dispatching station. More specifically, the grippingdevice 335 picks up one of the component parts 104 from the distal end326 of the conveyor 320 and places that component part 104, in a properorientation, in the respective dispatching station 314 for transferencevia dispatching lane 316 to the assembly apparatus 120, 220. Thecomponent part robotic manipulator 334 can be controlled by controller348 and electronics panel 350, in a manner well known to those ofordinary skill in the art.

In one embodiment of component part feed system 310, distal end 326 maybe provided with a moving inspection platform 344, which may be definedby a second conveyor belt that is independently moveable longitudinallyrelative to belt 330. In an alternative embodiment, the belt 330 of theconveyor 320 can be periodically stopped for allowing the identifier 338to identify the parts 104, the end of belt 330 serving as the inspectionplatform 344. Regardless of component part feed system embodiment,inspection platform 344 supports the component part 104 for inspectionby an identifier 338 and acquisition by robotic manipulator grippingdevice 335. The identifier 338, which may be a camera or other digitalimaging device, is disposed adjacent the distal end 326 of the conveyor320, above the inspection platform 344 for determining the type ofcomponent part 104 being inspected, and whether that part 104 requiresreorientation before it is acquired by the gripping device 335 and movedto the appropriate dispatching station 314. More specifically, theidentifier 338 scans the component part 104 located on platform 344 toidentify its type, size and/or orientation, and communicates informationregarding the present component part 104 to the component part roboticmanipulator 334, which then repositions the component part 104 asnecessary, acquires the component part 104 with its gripping device 335,and moves laterally along track 336 with the gripped component part 104to relocate it from the inspection platform 344 to the appropriate oneof dispatching stations 314 a-d.

In preferred embodiments of component part feed system 310, theidentifier 338 can be coupled to the conveyor 320 and/or coupled one ormore of the side rails 332 and/or coupled to the track 336 and/orcoupled to the component part robotic manipulator 334. When theidentifier 338 is disposed on the component part robotic manipulator334, the identifier 338 will be disposed adjacent the distal end 326when the component part robotic manipulator 334 moves along track 336 toalign itself with the longitudinal axis of conveyor belt 330 orinspection platform 344. The identifier 338 eliminates the need to havemultiple hoppers, multiple conveyors and multiple robotic manipulatorsas required by prior art component part feed systems. The identifier 338can be defined as a camera or any other suitable mechanism foridentifying the component parts 104.

In alternative embodiments of component part feed system 310, thecomponent part robotic manipulator 334 holds one of the component parts104 under the identifier 338 for identifying the part 104. In yetanother embodiment, the component part robotic manipulator 334 relocateseach component part 104 from the conveyor 320 to a separate, stationarysurface 346 for identification by the identifier 338 of the present part104 and any necessary repositioning thereof. On surface 346, which mayserve as inspection platform 344, the orientation of the identified part104 is adjusted as necessary by component part robotic manipulator 334prior to subsequent relocation to a dispatching station 314.

Each of the dispatching stations 314 associated with a dispatching lane316 receives one type of the component parts 104. More specifically, onedispatching station 314 and its dispatching lane 316 is dedicated toreceiving one of the different types of component parts 104 a-d andanother dispatching station 314 and associated dispatching lane 316 isdedicated to receiving a different one of the types of the plurality ofcomponent part types 104 a-d, etc., as mentioned above. For example, twodifferent component parts 104 can be further defined as a first parttype 104 a and a second part type 104 b, with the identifier 338identifying or distinguishing the first part type from the second parttype. The identifier 338 communicates the first and second part types104 a, 104 b to the component part robotic manipulator 334 such that thecomponent part robotic manipulator 334 moves along track 336 to relocatethe first part type 104 a from inspection platform 344 to firstdispatching station 314 a which is in communication with a firstdispatching lane 316 a; and moves along track 336 to relocate the secondpart type 104 b from inspection platform 344 to second dispatchingstation 314 b which is in communication with a second dispatching lane316 b. It is to be appreciated that the component parts 104 can befurther defined as including a third part type 104 c and a fourth parttype 104 d, etc., which are respectively fed to assembly apparatus 120,220 by component part feed system 310 via their respective dispatchingstations 314 c, 314 d and dispatching lanes 316 c, 316 d, withoutdeviating from the subject invention.

The dispatching lanes 316 are spaced from each other such that thecomponent part robotic manipulator 334 is disposed between the conveyor320 and the dispatching lanes 316 with the dispatching lanes 316disposed between the component part robotic manipulator 334 and theassembly apparatus 120, 220. Therefore, the gripping device of thecomponent part robotic manipulator 334 takes one of the component parts104 from the conveyor 320 and places that particular component part 104in the dispatching station 314 of the appropriate dispatching lane 316for delivering the part 104 to the component part receiving station 170,270 of assembly apparatus 120, 220, to perform the manufacturingoperation on the workpiece 100. The component part robotic manipulator334 moves back and forth along the track 336 and places the parts 104 inthe respective dispatching stations 314 of the appropriate dispatchinglanes 316 and in the appropriate orientation, thus eliminating the needfor skilled laborers to move the component parts 104 to the appropriatedispatching lanes 316 and properly orientating the component parts 104.Component part receiving stations 170, 270, dispatching stations 314,and dispatching lanes 316, are of a type known to those of ordinaryskill in the art, and are specially designed as a part feeder set for aspecific component part having a particular size, configuration and/ortype. A part feeder set for component part 104 a may include, forexample, associated receiving station 170 a, 270 a, dispatching station314 a, and dispatching lanes 316 a, . . . etc. . . . A receivingstation, dispatching station, and dispatching lane set, or a pluralityof such part feeder sets, may be of a general type that may be designedand manufactured for, and supplied to, assemblers of workpieces 100 byany of a number of sources such as, for example, Spectrum AutomationCompany of Livonia, Mich.; Air Way Automation, Inc. of Grayling, Mich.;or Visumatic Industrial Products of Lexington, Ky. Briefly, by way ofexample, the part feeder set may be of a type in which component parts104 are blown by compressed air, one at a time, through dispatching lane316 from its dispatching station 314 towards its associated receivingstation 170, 270. A buffer of a plurality of identical component partsmay be accumulated in the end of dispatching lane 316 adjacent receivingstation 170, 270, ready for use by assembly apparatus 120, 220.

Alternatively, the part feeder set may be of a type in which a pneumaticcylinder urges a component part 104 newly inserted into a dispatchingstation 314 into its dispatching lane 316, the newly inserted componentpart forming the end of a stack of component parts 104 that extendsalong the length of dispatching lane 316, the component part at theopposite end of the stack located in receiving station 170, 270. Thesecomponent parts are moved in daisy chain fashion through the dispatchinglane as the most recent addition to the stack is moved by the pneumaticcylinder, and are continuously supplied to receiving station 170, 270for ready use by assembly apparatus 120, 220.

For illustrative purposes only, the operation of the automated componentpart feed system 310 is discussed below. First, multiple different typesof the parts 104 are poured into the top opening 322 of the hopper 318.The oscillation mechanism vibrates the hopper 318 which in turn vibratesthe parts 104 for aiding in moving the parts 104 out of the bottomopening 324 of the hopper 318 and onto the belt 330 of the conveyor 320.The parts 104 move from the proximal end 328 toward the distal end 326of the conveyor 320 with the side rails 332 guiding the parts 104 intosingle file. As each part 104 reaches the identifier 338, the identifier338 determines the type of the part 104 and whether the part 104requires reorientation. The identifier 338 communicates this informationto the component part robotic manipulator 334, which travels along thetrack 336 to align itself with the conveyor 320 such that the grippingdevice can pick up that particular component part 104. Once the grippingdevice is gripping that particular part 104, the component part roboticmanipulator 334 travels along the track 336 again and aligns itself withthe appropriate dispatching station 314 to release that particular part104. The gripping device 335 then places the component part 104 in thedispatching station and in the appropriate orientation. The componentpart 104 then travels down the dispatching lane 316 to its connectedreceiving station 170, 270 of assembly apparatus 120, 220, whichperforms the manufacturing operation that assembles the component part104 to workpiece 100. The component part robotic manipulator 334 repeatsthe process of picking up the component parts 104 and moving thosecomponent parts 104 to the appropriate dispatching station 314.

While the invention has been described with reference to exemplaryembodiments, it will be understood by those skilled in the art thatvarious changes can be made and equivalents can be substituted forelements thereof without departing from the scope of the invention. Inaddition, many modifications can be made to adapt a particular situationor material to the teachings of the invention without departing from theessential scope thereof. Therefore, it is intended that the inventionnot be limited to the particular embodiments disclosed herein, but thatthe invention will include all embodiments falling within the scope ofthe appended claims.

1. A manufacturing system including an apparatus in which a pluralitydifferently configured workpieces requiring manufacturing operations areprocessed, the apparatus comprising: a work surface configured toreceive apparatus components and a plurality of differently configuredworkpieces, said work surface configured to support the apparatuscomponents and the plurality of differently configured workpiece ingeometrically accurate locations; a tool table adjacent said worksurface providing support for tooling and apparatus components requiredto process various manufacturing operations on the workpieces; and afirst robotic manipulator positioned adjacent to said work surface andsaid tool table and having a gripping device configured to grip at leastone of the apparatus components, said at least one of apparatuscomponents moved by the first robotic manipulator between said tooltable and said work surface; wherein said first robotic manipulator isprogrammed to selectively acquire tooling from said tool table toperform manufacturing operations on the plurality of differentlyconfigured workpieces.
 2. The apparatus set forth in claim 1, whereinthe work surface has a plurality of receptors configured to receiveapparatus components and a plurality of differently configuredworkpieces, said receptors being configured to support the apparatuscomponents and each of the plurality of differently configured workpiecein a geometrically accurate location.
 3. The apparatus set forth inclaim 1, wherein said first robotic manipulator positioned has agripping device configured to grip at least one of the plurality ofdifferently configured workpieces and move it relative to the worksurface.
 4. The apparatus set forth in claim 1, further comprising asecond robotic manipulator positioned adjacent to said work surface andhaving a gripping device configured to grip at least one of theplurality of differently configured workpieces and move it relative tothe work surface.
 5. The apparatus set forth in claim 1, wherein saidapparatus components comprise an anvil releasably mountable to said worksurface, said robotic manipulator supported by at least one of saidanvil and said work surface during performance of a manufacturingoperation of a workpiece.
 6. The apparatus set forth in claim 1, whereinsaid work surface includes receptors configured to receive a fixture toretain a workpiece in a geometrically accurate location.
 7. Theapparatus set forth in claim 1, wherein said work surface includesreceptors configured to receive a seal test fixture, the apparatusconfigured to perform sealability testing of a workpiece mounted to saidseal test fixture and provided with pressurized fluid through said worksurface.
 8. The apparatus set forth in claim 1, wherein said worksurface includes fluid and electrical connectors to provide and leastone of pneumatic, hydraulic and electrical service to at least one saidapparatus component.
 9. The apparatus set forth in claim 1, furtherincluding a controller electronically interconnected to said roboticmanipulator, control input to said robotic manipulator provided by saidcontroller.
 10. The apparatus set forth in claim 1, further including acontroller electronically interconnected with said work surface, controlinput to and control output from a said apparatus component,respectively provided or received by said controller as necessary toperform manufacturing operations on a workpiece.
 11. The apparatus setforth in claim 1, further including a second robotic manipulatorcooperating with the first robotic manipulator for transporting andoperating apparatus components, tooling, or one of the plurality ofdifferently configured workpieces.
 12. The apparatus set forth in claim1, further including a plurality of walls disposed about the worksurface, and against which an apparatus component is supported during amanufacturing operation on a workpiece mounted to a location said worksurface, said walls each moveable relative to said work surface locationbetween different positions at which said each wall is fixed relative tosaid work surface.
 13. The apparatus set forth in claim 1, furtherincluding a component part supply from which said first roboticmanipulator obtains a component part on tooling attached thereto, thefirst robotic manipulator adapted to install the obtained component partin the workpiece supported by said work surface.
 14. A method ofassembling first and second differently configured workpieces,comprising the steps of: releasably affixing first assembly apparatuscomponents to a work surface using at least one of a plurality ofreceptors positioned in a geometrically accurate location; releasablyaffixing the first workpiece to the work surface using at least one ofthe plurality of receptors thereby positioning the first workpiece in ageometrically accurate location; supporting assembly apparatuscomponents necessary to assemble the first workpiece relative to thework surface; positioning a robotic manipulator carrying toolingnecessary to assemble the first workpiece and the first component partrelative to the first workpiece; supporting tooling necessary toassemble the first workpiece against undesired movement relative to thefirst workpiece with at least one of an assembly apparatus component andthe work surface; performing a first assembly operation by operatingsaid tooling and installing the component part to the first workpiece;removing the first workpiece from the work surface; releasably affixingsecond assembly apparatus components to the work surface using at leastone of the plurality of receptors positioned in a geometrically accuratelocation; releasably affixing the second workpiece to the work surfaceusing at least one of the plurality of receptors thereby positioning thesecond workpiece in a geometrically accurate location; supportingassembly apparatus components necessary to assemble the first workpiecerelative to the work surface; positioning a robotic manipulator carryingtooling necessary to assemble the second workpiece and a component partrelative to the second workpiece; supporting tooling necessary toassemble the second workpiece against undesired movement relative to thesecond workpiece with at least one of an assembly apparatus componentand the work surface; performing a second assembly operation byoperating said tooling and installing the component part to the secondworkpiece; and removing the second workpiece from the work surface. 15.The method set forth in claim 14, further comprising replacing thetooling used in performing the first assembly operation withinterchangeable, different tooling prior to performing the secondassembly operation.
 16. The method set forth in claim 14, wherein saidstep of affixing said assembly apparatus components to the work surfaceis further defined by affixing testing devices to the work surface fortesting the workpiece.
 17. The method set forth in claim 16, whereinsaid step of affixing testing devices to the work surface for testingthe workpiece is further defined by the steps of: affixing a leak testplate to the work surface; affixing the first workpiece to the leak testplate after performing a first assembly operation; sealing the firstworkpiece; and providing fluid under pressure to the sealed firstworkpiece.
 18. The method set forth in claim 14, further including thestep of using at least one robotic manipulator for moving the workpiecesand the assembly apparatus components to the work surface.
 19. Themethod set forth in claim 14, wherein at least one of said first andsecond assembly operations include installing differently configuredcomponent parts to the first and second workpieces.
 20. The method setforth in claim 19, wherein one of said first and second assemblyoperations includes a pressing operation, and the other includes ascrewing operation.
 21. An automated feed system for supplying componentparts to a manufacturing operation, said feed system comprising: ahopper for receiving a plurality of differently configured componentparts; a conveyor in communication with said hopper and having aproximal end and a distal end with said hopper disposed adjacent saidproximal end with said hopper cooperating with said conveyor for movingthe component parts from said proximal end toward said distal end;opposing side rails extend between said hopper and said conveyor distalend for guiding the component parts toward said distal end; a roboticmanipulator movable along a track for moving the component parts fromsaid distal end and away from said conveyor; and an identifier disposedadjacent said distal end with said identifier in communication with saidrobotic manipulator, each of the component parts identified by theidentifier.
 22. A feed system as set forth in claim 21 further includinga plurality of dispatching lanes spaced from each other, each of theidentified component parts relocated by the robotic manipulator to anassociated dispatching lane from the conveyor distal end.
 23. A feedsystem as set forth in claim 22 wherein the component parts are furtherdefined as a first component part type and a second component part typewith said identifier identifying the first component part type from thesecond component part type and communicating the first and secondcomponent part types to the robotic manipulator such that the identifiedfirst component part type is moved by the robotic manipulator to one ofsaid dispatching lanes and the identified second component part type ismoved by the robotic manipulator to another one of said dispatchinglanes.
 24. A feed system as set forth in claim 22 wherein said roboticmanipulator includes a gripping device by which one of the componentparts is grasped and moved by the robotic manipulator to one of saiddispatching lanes.